Apparatus for the construction of concrete structures

ABSTRACT

A concrete structure, e. g. a dwelling house, is disclosed to include a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof. The monolithic divider slab encases conduits for providing electrical service and suitable piping means for providing plumbing services. The structure is disclosed to be constructed by pouring a base slab on the desired site, erecting a form on the base slab after curing to define an opening for concrete for the monolithic divider slab, filling the opening so defined with concrete and allowing it to cure, removing the forms and positioning a precast concrete roof on and in secure engagement with the monolithic divider slab. The roof may be poured conveniently adjacent the base slab site and thereafter lifted into position on the monolithic divider slab. Where the roof is in sections, a novel sealing structure is disclosed for securing the joint at the interface of the sections. Also disclosed is a novel form arrangement and structure which utilizes sectionalized and pivotally related form sections to accommodate the pouring of the monolithic divider slab as a single pour and to enable the set-up, knock-down and transportation of the forms with a minimum of difficulty.

United States Patent Belluscio 1 July 18, 1972 [72] Inventor: Anthony W.Belluaclo, l6ll E. Elizabeth Ave, Linden, NJ. 10453 qsn |m.c| ..E04bI/005s FleldotSearch ..52 741.743,745.238

[56] References Cited UNITED STATES PATENTS 4/1967 Smith ..52/743 9/l968Comment 7/1969 Rice ..52/743 Primary Examiner- Patrick D. LawsonAttorney-Popper, Bain, Bobis & Gilfillan [57] ABSTRACT A concretestructure, e. g. a dwelling house, is disclosed to include a base slab,a monolithic divider slab for defining an outside wall and a pluralityof interior walls, and a concrete roof. The monolithic divider slabencases conduits for providing electrical service and suitable pipingmeans for providing plumbing services.

The structure is disclosed to be constructed by pouring a base slab onthe desired site, erecting a form on the base slab after curing todefine an opening for concrete for the monolithic divider slab, fillingthe opening so defined with concrete and allowing it to cure, removingthe forms and positioning a precast concrete roof on and in secureengagement with the monolithic divider slab. The roof may be pouredconveniently adjacent the base slab site and thereafter lifted intoposition on the monolithic divider slab. Where the roof is in sections,a novel sealing structure is disclosed for securing the joint at theinterface of the sections.

Also disclosed is a novel form arrangement and structure which utilizessectionalized and pivotally related form sections to accommodate thepouring of the monolithic divider slab as a single pour and to enablethe set-up, knock-down and transportation of the forms with a minimum ofdifficulty.

5 Claims, 10 lh'awing Figures PATENTEnJuu 81912 3.678; 975 SHEET 1 OF 5FIG. 2 l0 m/vavrox? ANTI-ION) W BELLUSC/O By POPPER, 54w, 808/5 a GILF/LLA/V ATTORNEYS PATENTEU .wu 81972 SHEET 30F 5 PATENTEB JUL I 8 I972SHEET 5 OF 5 APPARATUS FOR THE CONSTRUCTION OF CONCRETE STRUCTURESBACKGROUND OF THE INVENTION One of the principal aims of governments theworld over, those engaged in the housing industry, and those concernedwith social reform, is the development of satisfactory low cost housing.

Many attempts have been made to develop a building structure which islow in cost and suitable for use as a dwelling house. Included among theproposals have been assembly of the structure from pre-cast concretesections, prefa brication of the structure at a plant and assembly atthe site, and total fabrication of the building structure at an off-sitelocation and transfer to the site. Although each of the foregoing hasbeen successful to some extent, none has provided a low cost structurewhich is (a) physically large enough to accommodate comfortably anaverage family, (b) structurally sound against decay and leakage,particularly in tropical climates, and (c) sufficiently attractive toinstill in the owner a sense of pride and desire to maintain thestructure in good condition.

It is the principal object of the invention, therefore, to provide abuilding structure and methods and apparatus for the constructionthereof which enable the construction of an inexpensive yet attractiveand fully functional structure, which structure may be utilized as alow-cost family dwelling unit, a resort dwelling or the like.

SUMMARY OF THE INVENTION The foregoing principal object as well asothers not enumerated are accomplished by a concrete building structureaccording to the invention which may include a base slab for defining afloor and foundation, a monolithic divider slab for defining an outsidewall and a plurality of interior walls, the divider slab being securedto the base slab, a concrete roof means and means for rigidly securingthe roof means to the monolithic divider slab.

The foregoing concrete building structure according to the invention maybe constructed according to the method of the invention, the steps ofwhich may include pouring a concrete base slab on the site of thebuilding to define a foundation and floor and allowing the base slab tocure, erecting forms on the base slab to provide an opening forreceiving concrete to define a monolithic divider slab, filling theopening with concrete to define the monolithic divider slab, curing theconcrete of the monolithic divider slab, removing the forms, positioninga roof section on the monolithic divider slab, and securing the roof tothe monolithic divider slab.

The invention also contemplates a novel form apparatus for enabling theconstruction of the above-described divider slab as a monolithic slab.

Finally, the invention contemplates a water-tight joint for sealing theinterface between first and second concrete slabs which may include aflange on one end of each of the first and second slabs, each flangehaving one surface normal to the basic plane of the slabs and a surfaceextending obliquely to the basic plane of the slabs, the flangescooperating to define a mating joint having a keystone cross-sectionalconfiguration, and a resilient means extending over the flanges and inresilient frictional engagement with each of the surfaces extending tothe basic plane of the slabs.

BRIEF DESCRIPTION OF THE DRAWINGS A more complete understanding of thepresent invention may be had from the following detailed description,particularly when considered in the light of the accompanying drawingswherein:

FIG. I is a floor plan of a building according to the inventron;

FIG. 2 is an elevational view of the building of FIG. I;

FIG. 3 is a plan view of an arrangement of forms for use in the pouringof a monolithic divider slab in constructing the building shown in FIG.I;

FIG. 4 is an elevational view similar to FIG. 2 but of the formarrangement shown in FIG. 3;

FIG. 5 is a view similar to FIG. 3 but showing the forms in partiallyfolded positions to facilitate their removal after the completion of thepouring of a monolithic divider wall shown in FIG. 1;

FIG. 6 is detailed view of corner locking structure for securing fonnsections of FIGS. 4 and 5;

FIG. 7 is a detailed view of tongue and key locking structure forsecuring the form sections of FIGS. 4 and 5;

FIG. 8 is a partial perspective view of a typical corner form structure;

FIG. 9 is an exploded perspective view of the concrete building of theinvention; and

FIG. 10 is a partial cross-sectional view through the plane I010 of FIG.9.

DETAILED DESCRIPTION Referring to FIGS. I and 2, a building structureaccording to the invention is designated generally by reference numeralI0. Broadly, building 10 comprises a base slab 12, a monolithic dividersection 14 and a roof 16.

The base slab I2 is a monolithic slab which serves as both foundationand floor for building 10. The slab is formed of concrete approximately6 to 8 inches thick and provided with suitable reinforcing rods.

The monolithic divider section 14 is also a monolithic concretestructure, i.e. a structure formed by a single pour of concrete into atotally communicating form opening. Divider section 14 is structurallysecured to base slab 12 by common reinforcing rods (FIG. 9) which areprepositioned in the base slab and which extend into the divider slab.

The roof l6 for building 10 comprises two pre-cast concrete sections 17and 18 which are secured to divider slab 14 by bolts 20 (FIG. 9), as isdiscussed below, and sealed at their interface by a novel sealing joint22 the details of which are discussed below.

Considering the lay-out shown in FIG. 1, monolithic divider slab I4 canbe seen to divide the area above base slab I2 into a terrace area 24, aliving room-dining room area 25, a bedroom area 26, a kitchen area 27and a bathroom area 28. Bedroom area 26 is divided into three individualbedrooms 30, 31 and 32 by the provision of closet sections 34 and 35.

Monolithic divider slab 14 includes an outside wall portion 38 whichdefines the outer perimeter of building 10 and a plurality of interiorwall portions 40-43 which separate the bedroom 30 from the living-diningroom area 25, the bedroom 32 from the bathroom area 28, the bathroomarea 28 from the kitchen area 27, and the kitchen area 27 from theliving-dining room area 25, respectively.

The outside wall portion is provided with a plurality of suitable windowopenings 45 which may be closed by glass windows of well knownconstruction or by windows of the slotted or shutter type as are ofienutilized in tropical climates.

An opening is provided between the terrace area 24 and the living-diningroom area 25 in which is mounted a door 47. Similarly, a door 48 ismounted in an opening in outer wall 38 to provide access between kitchenarea 27 and the outside of building I0. Interior doors 50, 51, 52 and53, respectively, are provided to establish privacy for bedrooms 30, 31and 32 and for bathroom area 28.

As noted above, bedrooms 30, 31 and 32 are separated by closet sections34 and 35. In this regard, closet sections 34 and 35 do not form part ofthe monolithic divider slab I4 but rather are preconstructed closetsections of a type which are generally available on the market or whichmay be constructed on site. Each section may be secured to the innersurfaces of outside wall 38 by suitable stud bolts 55 which may bemounted in divider slab 14 during the pouring thereof. In this regard,it is clear that either or both of closet sections 34 and 35 can beomitted to make the building structure a onebedroom or two-bedroomstructure.

Electrical and plumbing services are provided by positioning,prior tothe pouring of concrete, electrical conduit means and plumbing pipelines within the forms for forming the monolithic divider slab. Theconduits and pipe lines are retained in proper position by securingtheir ends to suitable openings in the concrete forms, which openingsare provided for that purpose.

Thus, building comprises a structure having three basic elements, i.e.base slab, monolithic divider slab and roof. Because of the fact thatthe divider slab is monolithic, the structure is expedient to constructand thus relatively inexpensive.

Considering therefore the manner of constructing building 10, suitableforms (not shown) are erected on the proposed building site toaccommodate the pouring of base slab 12. As is evident from FIG. 9, theforms for the base slab of building 10 define a rectangular opening andmay be of suitable depth, e.g. six to eight inches, as may beappropriate for the site conditions.

In order to facilitate rapid construction, a quick drying cement may beutilized for not only the base 12, but also for the monolithic dividerslab 14 and roof sections 17 and 18. An acceptable cement for use inconstructing buildings according to the invention is High Early asmanufactured by the Portland Cement Co.

With the forms for base slab 12 properly positioned, the concretetherefor is poured and allowed to cure as required. Additionally, aplurality of reinforcing rods 57 are positioned so as to be set at theirbottoms within base slab l2 and to extend upwardly from base 12 toultimately be received within monolithic divider slab 14. Thereafter,the base slab forms are removed, for example to a next adjacentconstruction site for use in pouring another base slab.

After base 12 has been poured and allowed to cure, the forms forconstructing monolithic divider slab 14 are positioned over base slab 12in preparation for the pouring of the divider slab. As best may be seenin FIGS. 3, 4 and 5, the forms which are utilized for pouring monolithicdivider slab 14 include a perimeter form members 60 and four interiorform members, namely a living-dining room area form member 62, a bedroomarea form member 64, a bathroom area form member 66 and a kitchen areaform member 68. Thus, form members 60, 62, 64, 66 and 68, whenpositioned and secured as shown in FIG. 3, cooperate with base slabe 12to define a single opening into which concrete can be poured to formmonolithic divider slab 14.

Considering the construction of the fonns in greater detail, perimeterform member 60 is best seen in FlG. 5 to comprise a first perimetersection 70, a second perimeter section 71 and a third perimeter section72. Perimeter sections 70 and 71 and 71 and 72 are pivotally connectedby hinge means 73 and 74, mating sections of which hinges are securedsuch as by welding on adjacent edges of the perimeter form sections. Thehinges may be of conventional construction such as those shown in FIG.8, however, they are mounted on the outer surface of form sections 70,71 and 72 so as to present a smooth surface on the concrete engagingside of the forms. Thus each of the form sections comprises a pluralityof sheets which may be of a suitable material such as steelv The sheetsare positioned and secured to define the outer surface configuration ofbuilding 10. Additionally, each sheet may be provided with one or morestifl'eners, e. g. the angle iron stifieners 75 on form section 71 asshown in FIG. 4. The edges of form sections 70 and 72 which are furthestremoved from the pivoted edges are provided with locking means to securethe two form sections together to define the complete perimeter form 60.Locking means which are considered to be fully satisfactory are shown inFIG. 6 and comprise slotted straps 77 and 78 which may be rigidlysecured such as by welding to form sections 70 and 72, respectively.Each of straps 77 and 78 is provided with a slot, through which slotsextend bolts 80 and 81. The base of bolt 80 is rigidly secured to theouter surface of form section 72 by welding. Similarly, the base of bolt81 is secured to the outer surface of form section 70 by welding. Whenthe edges of form sections 70 and 72 are juxtaposed, the threadedportion of bolt extends through the slot in strap 77 and the threadedportion of bolt 81 extends through the slot in strap 78. Washers andnuts are then positioned on the bolts 80 and 81, and the nuts aretightened against the surfaces of straps 77 and 78 until the formsections 70 and 72 are rigidly secured in concrete supporting position.Thus, perimeter form 60 can be fully assembled by positioning formsection 70, positioning form section 71 such as to engage hinges 73,positioning form section 72 such as to engage hinges 74, pivoting formsections 70, 71 and 72 together until bolts 80 and 81 extend through theslots in straps 77 and 78, and thereafter rigidly securing the assemblyby tightening the nuts on bolts 80 and 81.

Interior forms 62, 64, 66 and 68 are similar to perimeter form 60 withthe exceptions that each includes three or more form sections pivotedtogether to facilitate assembly and dis assembly, each is constructedwith the hinges and stifl'eners on the inner surfaces so as to presentan outwardly facing smooth surface for satisfactorily forming theconcrete, and each utilizes tongue and wedge securing devices ratherthan the strap and bolt securing devices used for the perimeter form 60.

Referring to FIGS. 3, 5 and 7, therefore, living-dining room area form62 can be seen to comprise five form sections 83, 84, 85, 86 and 87.Form sections 83 and 84 are pivotally connected by hinges 90, formsections 84 and 85 are pivotally connected by hinges 91, form sections85 and 86 are pivotally connected by hinges 92, and form sections 86 and87 are pivotally connected by hinges 93.

The pivoted joints for adjacent form sections are identical inconstruction and one such typical construction is shown in FIG. 8. Morespecifically, FIG. 8 shows a partial perspective view of the edgebetween living-dining room form sections 85 and 86, which sections areivotally connected by hinges 92. Each hinge 92 comprises an upper leaf95 and a lower leaf 96 pivotally connected by a pintle 98. The hingeleaves 95 and 96 are secured to form sections 85 and 86 respectively bywelding or like securing methods generally known in the art.Additionally, the adjacent fonn sections 85 and 86 are provided withangle stiffeners 99, 100, which stiffeners are spaced vertically topermit unobstructed pivoting of the form sections.

Bedroom area form 64 includes first, second, third, fourth and fifthbedroom form sections 101 through 105 respectively. The form sectionsare pivotally connected, in the manner described above with respect toform sections 85 and 86, by hinges 108-111. Similarly, bathroom areaform 66 comprises first, second and third bathroom form sections 113,114 and 115 which are pivotally connected by hinges 118 and 119.Additionally, kitchen area form 68 comprises first, second and thirdkitchen form sections 121, 122 and 123, pivotally connected by hinges126 and 127.

As was noted above, the interior forms 62, 64, 66 and 68 areinterconnected by tongue and wedge type securing means. Thus, fifthliving room form section 87 is secured to first bedroom form section 101by a plurality of spaced tongue and wedge securing means 130. Similarly,first and third bathroom form sections 113 and 115 are secured to fifthbedroom form section 105 by a plurality of spaced tongue and wedgesecuring means 132 and 133 respectively. Fifth bedroom form sec tion 105is also secured to second kitchen form section 122 by tongue and wedgesecuring means 135.

In addition to being secured to fifth bedroom form section 105, secondkitchen form section 122 is also secured to first living-dining roomform section 83 by vertically spaced tongue and wedge securing means137. Finally, first and third kitchen form sections 121 and 123 aresecured to perimeter form sec tion 71 by a plurality of verticallyspaced tongue and wedge securing means 139 and 140, respectively.

Although the specific relationship of the elements may vary from jointto joint, each of the tongue and wedge securing means utilized forsecuring two form sections according to the invention includes a slottedtongue on one form section which is received through a suitable openingin the other form section, and a wedge which can be driven into the slotin the tongue to draw the sections tightly together and to maintain themin rigidly secured relationship.

A typical tongue and wedge securing means according to the invention istongue and wedge 135, shown in perspective in FIG. 7 which secures fifthbedroom form section 105 with second kitchen form section 122. Referringtherefore to FIG. 7, tongue and wedge means I35 can be seen to include atongue I40 wich is rigidly secured as by welding, to form section 105.Tongue 140 extends through an opening 141 in form section I22sufficiently far to expose a slot 142 formed in tongue 140. Receivedthrough slot 142 is a wedge device I44 which is tapered such that as itis inserted through slot I42, it bears against the inner surface of slot142 and the surface of form section 122 to draw tongue I40 throughopening 14! thereby drawing form secu'on I05 tightly against formsection I22.

As noted above, the forms 60, 62, 64, 66 and 68 are positioned on baseslab 12 after it has been poured and been allowed to cure. The forms maybe positioned in any sequence found to be most appropriate for theconstruction crew. When completely positioned, however, they appear asshown in FIG. 3, i.e. they cooperate to define a single opening intowhich concrete is poured to form monolithic divider slab I4. Dividerslab 14 is structurally secured to base slab I2 by reinforcing rods I46(FIG. 9) which are pre-set in base slab 12 in such positions as toextend into the opening defined by forms 60, 62, 64, 66 and 68 whenassembled.

As is evident from the various Figures, openings are provided in thewalls of building 10 to allow for the mounting of windows and doors. Theopenings are formed by positioning between the wall defining forms, boxstructures which preclude the entry of concrete into the opening spaceduring pouring. The box structures may be of wood as is conventional, orthey may be defined by the actual window and door sash structures. Whenthe sash structures are utilized, the completion of the window or doorinstallation afler pouring of concrete requires only that the window ordoor be mounted within the pre-set sash.

It has been found that where openings are provided in the forms toaccommodate window or door spaces, it is desirable to provide additionalsupport means adjacent the openings, e.g. drawbolts 148 (FIG. 4), inorder to avoid the occurrence of deflection or buckling in the formsduring pouring and setting of the concrete which might result in leakageof concrete past the opening-defining box structures.

When constructing building I0 according to the invention, the monolithicdivider slab I4 is constructed by positioning and securing forms 60, 62,64, 66 and 68 on base slab 12 so that reinforcing rods 146 are enclosedthereby. Suitable boxes for defining window and door openings are thenpositioned as required and secured within the form sections. With theforms completely assembled, i.e. disposed as shown in FIG. 3, concreteis poured and thereafter allowed to cure.

Once the concrete of divider slab 14 has cured, forms 60, 62, 64, 66 and68 may be removed for use in a next subsequent building. Removal can beaccomplished easily be dis engaging all the tongue and wedge securingdevices as well as the bolt and slotted strap securing devices, foldingthe form sections about the hinges away from the now constructed dividerslab I4, and removing, eg by crane, the form sections from the site ofbuilding 10 to a storage area or a next sub sequent building site.

Referring briefly to FIG. 9, it can be seen that there are a pluralityof studs extending upwardly from the upper edge of divider slab I4 aswell as a plurality of studs 55 extending into bedroom area 26 from theinner surface of slab 14. As was noted above, studs 55 are bolts forsecuring closet sections 34 and 35 within slab l4. Studs 20 are forsecuring roof sections 17 and 18 into slab 14 after slab I4 has beenpoured and cured.

Thus, after slab 14 has been poured and cured, and after forms 60, 62,64, 66 and 68 have been removed, roof 16 may be positioned. In thisregard, the sections 17 and I8 of roof I6 may be pre-cast prior toshipment to the site, or, more desirably, they may be poured at thesite. It is considered to be economically desirable to construct formsfor roof sections 17 and I8 on the building site adjacent the base slabposition, and thereafier pouring bath the base slab and the roofsections at the same time. Roof sections I7 and 18 are simple in form,see FIG. I0, and thus are well adapted for on site construction.Referring to FIG. I0, each roof section 17 and 18 comprises a centerportion I5], 152, a peripheral ledge 155, 156, and a flange I59, I60.Each flange I59 and 160 has one surface norms] to the basic plane ofcenter portions 15! and 152, and a surface I6I, I62 extending obliquelyto the basic plane of center portions 151 and I52. The surfaces offlanges I59 and I60 which are normal to the basic plane of centerportions l5l and I52 are provided with a tongue 163 and a groove I64,respectively. Thus, when roof sections 17 and I8 are positioned on slabI4 to define roof I6, the normal surfaces of flanges 159 and I60including tongue I63 and groove I64, are in surface to surfaceengagement and the flanges cooperate to define a mating joint having akeystone cross-sectional configuration. With the roof sections sopositioned, the joint therebetween is sealed by providing a U-shapedresilient cover strip I65 which extends longitudinally over the flangesbetween ledges and 156 and around flanges I59 and I60 to engage obliquesurfaces I61 and 162.

Assuming that roof sections I7 and I8 have been poured on site, they areallowed to cure and thereafter are positioned on slab I4 by suitablemeans such as a crane. Each of the ledges 155 and 156 is provided withbolt holes (not shown) for receiving stud bolts 20 therethrough, whichbolts can then be provided with nuts for securing the roof sections inthe manner conventionally known in the art. Additionally, buil dup ofwater on roof sections 17 and I8 is precluded by providing suitabledrain openings through ledges 155 and I56. After the two roof sectionsare secured, resilient sealing strip 22 is positioned over flanges I59and 160 and the building 10 is now ready for interior finishing.

It can be seen from the foregoing that the present inventioncontemplates the construction of a novel building structure by the novelmethod of pouring a concrete base slab on a building site for defining afoundation and a floor, allowing the base slab to cure, erecting formson the base slab to provide an opening for receiving concrete to definea monolithic-divider slab including outside wall forming portions andinterior wall forming portions, filling the opening with concrete todefine the monolithic divider slab to cure, removing the forms,positioning a concrete roof on the monolithic divider slab, and securingthe roof to the monolithic divider slab.

It is considered to be manifest that many modifications and variationsof the present invention can be made without departing from the spiritand scope thereof.

I claim:

1. Apparatus for use in constructing a concrete building having a baseslab, a monolithic divider slab for defining an outside wall and aplurality of interior walls, and a concrete roof means, in saidapparatus including:

form means for cooperating with said base slab to define an opening forreceiving concrete to form said monolithic divider slab wherein saidform means includes a plurality of pi otally secured sections fordefining the outer boundary of said outside wall and a plurality ofsections for defining the inner boundaries of said outside walls and theboundaries of said interior walls.

2. Apparatus according to claim I wherein concrete building includes aliving and dining room area, a kitchen area, a bathroom area and abedroom area, and wherein said forms include:

a first form member having three sections for defining the outersurfaces of said outside walls, and

four additional form members for defining the inner surfaces of saidoutside walls and the surfaces of said interior walls.

said living and dining room area. one of said additional form membersdefines the inner surface of the walls of said bedroom area, one of saidadditional form members defines the inner surface of the walls of saidbathroom area, and one of said additional form members defines the innersurface of the walls of said kitchen area.

1. Apparatus for use in constructing a concrete building having a base slab, a monolithic divider slab for defining an outside wall and a plurality of interior walls, and a concrete roof means, in said apparatus including: form means for cooperating with said base slab to define an opening for receiving concrete to form said monolithic divider slab wherein said form means includes a plurality of pivotally secured sections for defining the outer boundary of said outside wall and a plurality of sections for defining the inner boundaries of said outside walls and the boundaries of said interior walls.
 2. Apparatus according to claim 1 wherein concrete building includes a living and dining room area, a kitchen area, a bathroom area and a bedroom area, and wherein said forms include: a first form member having three sections for defining the outer surfaces of said outside walls, and four additional form members for defining the inner surfaces of said outside walls and the surfaces of said interior walls.
 3. Apparatus according to claim 2 wherein said sections of said first form member are joined pivotally at adjacent edges thereof.
 4. Apparatus according to claim 2 wherein each of said four additional form members include a plurality of sections pivotally secured at adjacent edges.
 5. Apparatus according to claim 2 wherein one of said additional form members defines the inner surface of the walls of said living and dining room area, one of said additional form members defines the inner surface of the walls of said bedroom area, one of said additional form members defines the inner surface of the walls of said bathroom area, and one of said additional form members defines the inner surface of the walls of said kitchen area. 